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The Heat Exchanger

Thermal Management for a Sustainable Future

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Achieved a surface area 14 times higher than traditional designs
Met pressure drop goals within a few iterations
Exceeded heat exchanger efficiency targets, propelling advanced manufacturing towards sustainability

The Challenge

In the quest to mitigate the 13.2 Gt of energy-related CO2 emissions from heating and cooling, our collaboration with TRUMPF aimed to overhaul the conventional heat exchanger design. This initiative sought to address the inefficiencies of existing technologies, leveraging nature-inspired configurations for superior thermal management in an era of escalating global temperatures.

The Process

Hyperganic and TRUMPF embarked on pioneering algorithmic engineering, employing Hyperganic Core to automate the design of versatile, efficient heat exchangers. Inspired by natural principles, like fractal branching and phyllotaxis arrangements akin to sunflower seed patterns, this approach allowed for rapid iterations and adaptable designs, culminating in a novel heat exchanger with unparalleled thermal efficiency and minimized resource usage.

The Results

Our collaborative innovation resulted in an algorithmically designed heat exchanger that not only surpasses the performance of conventional models but also symbolizes a leap towards the sustainable industrial revolution. With its significantly increased surface area and optimized heat exchange capabilities, this breakthrough demonstrates the power of merging digital manufacturing with algorithmic engineering to achieve environmental and efficiency milestones.

By redefining design paradigms through nature-inspired algorithms, we're setting new standards for the future of advanced manufacturing, ensuring that as the demand for cooling grows, our solutions evolve sustainably and efficiently.

Addendum 20/11/23

In a recent collaboration, the heat exchanger designed by Hyperganic has been printed by Bundesanstalt für Materialforschung und -prüfung (the German Federal Institute for Materials Research and Testing, also known as BAM). The heat exchanger was printed by BAM’s PBF-LB/M printer, which utilises four lasers instead of one, reducing production time from 7 to 3 days, but with additional risks of overheating. These issues were mitigated by Hyperganic’s algorithmically engineered and highly complex design, and the final product was showcased at Formnext 2023 as a demonstration of Hyperganic’s technological solutions.